Sta-Rite FLC-L Installation Manual

293 Wright Street, Delavan, WI 53115

Phone: [phone]

Fax: [phone]

Web Site: Sta-Rite.com

OWNER’S MANUAL

Convertible Deep Well Jet Pumps

NOTICE D’UTILISATION

Pompe à éjecteur transformables pour puits profonds

MANUAL DEL USUARIO

Bombas convertibles tipo “jet” para pozos profundos

Installation/Operation/Parts		Installation/Fonctionnement/Pièces Instalación/Operación/Piezas

For further operating, installation, or maintenance assistance:

Pour plus de renseignements concernant l’utilisation, l’installation ou l’entretien,

Para mayor información sobre el funcionamiento, instalación o mantenimiento de la bomba:

Call 1-888-782-7483	Composer le 1 [phone]		Llame al 1-888-782-7483
English . . . . . . . . . . .	Pages 2-12 Français . . . . . . . . .	Pages 13-23	Español . . . . . . .	Paginas 24-34

© 2011

S920 (7/25/2011)

Safety	2

Important Safety Instructions

SAVE THESE INSTRUCTIONS - This manual contains important instructions that should be followed during installation, operation, and maintenance of the product. Save this manual for future reference.

This is the safety alert symbol. When you see this symbol on your pump or in this manual, look for one of the following signal words and be alert to the potential for personal injury!

indicates a hazard which, if not avoided, will result in death or serious injury.

indicates a hazard which, if not avoided, could result in death or serious injury.

indicates a hazard which, if not avoided, could result in minor or moderate injury.

NOTICE addresses practices not related to personal injury.

Carefully read and follow all safety instructions in this manual and on pump..

Keep safety labels in good condition. Replace missing or damaged safety labels.

Electrical Safety

Risk of electrical shock.. Capacitor voltage may be hazardous. To discharge motor capacitor, hold insulated handle screwdriver BY THE HANDLE and short capacitor terminals together. Do not touch metal screwdriver blade or capacitor terminals. If in doubt, consult a qualified electrician.

General Safety

Risk of burns.. Do not touch an operating motor. Motors are designed to operate at high temperatures. To avoid burns when servicing pump, allow it to cool for 20 minutes after shut-down before handling.

Do not allow pump or any system component to freeze. To do so will void warranty.

Pump water only with this pump.

Periodically inspect pump and system components. Wear safety glasses at all times when working on pumps.

Keep work area clean, uncluttered and properly lighted; store properly all unused tools and equipment.

Keep visitors at a safe distance from the work areas.

Risk of explosion.. Pump body may explode if used as a booster pump unless relief valve capable of passing full pump flow at 75 psi is installed.

WARNING

Hazardous voltage..

Can shock, burn, or cause death.

Ground pump before connecting to power supply. Disconnect power before working on pump, motor or tank.

Wire motor for correct voltage.. See “Electrical” section of this manual and motor nameplate..

Ground motor before connecting to power supply..

Meet National Electrical Code, Canadian Electrical Code, and local codes for all wiring..

Follow wiring instructions in this manual when connecting motor to power lines..

WARNING

Hazardous pressure!

Install pressure relief valve in discharge pipe.

Release all pressure on system before working on any component.

Warranty	3

Limited Warranty

STA-RITE warrants to the original consumer purchaser (“Purchaser” or “You”) of the products listed below, that they will be free from defects in material and workmanship for the Warranty Period shown below.

	Product	Warranty Period
	Water Systems Products — jet pumps, small centrifugal pumps,	whichever occurs first:
		12 months from date of original installation,
	submersible pumps and related accessories
		or 18 months from date of manufacture
	Pro-Source™ Composite Tanks	5 years from date of original installation
	Pro-Source™ Steel Pressure Tanks	5 years from date of original installation
	Pro-Source™ Epoxy-Lined Tanks	3 years from date of original installation
	Sump/Sewage/Effluent Products	12 months from date of original installation, or
		18 months from date of manufacture

Our warranty will not apply to any product that, in our sole judgement, has been subject to negligence, misapplication, improper installation, or improper maintenance. Without limiting the foregoing, operating a three phase motor with single phase power through a phase converter will void the warranty. Note also that three phase motors must be protected by three-leg, ambient compensated, extra-quick trip overload relays of the recommended size or the warranty is void.

Your only remedy, and STA-RITE’s only duty, is that STA-RITE repair or replace defective products (at STA-RITE’s choice). You must pay all labor and shipping charges associated with this warranty and must request warranty service through the installing dealer as soon as a problem is discovered. No request for service will be accepted if received after the Warranty Period has expired. This warranty is not transferable.

STA-RITE SHALL NOT BE LIABLE FOR ANY CONSEQUENTIAL, INCIDENTAL, OR CONTINGENT DAMAGES WHATSOEVER.

THE FOREGOING WARRANTIES ARE EXCLUSIVE AND IN LIEU OF ALL OTHER EXPRESS AND IMPLIED WARRANTIES, INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE. THE FOREGOING WARRANTIES SHALL NOT EXTEND BEYOND THE DURATION EXPRESSLY PROVIDED HEREIN.

Some states do not allow the exclusion or limitation of incidental or consequential damages or limitations on the duration of an implied warranty, so the above limitations or exclusions may not apply to You. This warranty gives You specific legal rights and You may also have other rights which vary from state to state.

This Limited Warranty is effective June 1, 2011 and replaces all undated warranties and warranties dated before June 1, 2011.

STA-RITE INDUSTRIES

293 Wright Street • Delavan, WI U.S.A. 53115

Phone: [phone] • Fax: [phone] • Web Site: Sta-Rite.com

Typical Installations	4

Piping omitted for clarity

Drive over Suction

Discharge

Suction

over

Drive

Drive Pipe sends water

down the well to drive water up through the

Suction Pipe

to Pump Suction

819 0495

Figure 1: Drive and Suction Functions

If well head and pump don t match, use a reversing adapter or twist reinforced flexible pipe to connect pump to well head.

Well

Head

Suction

(Larger)

Pipe Drive (Smaller)

Pipe

328 0395

Figure 2: Reversed Connections

to Well

Tap clamp to seat it

A

Install venturi in larger port in front

of pump.

820 0495

Figure 3: Mount Ejector –

Shallow Well

"Double Pipe"	"Single Pipe"
(4" and Larger	(2" and 3"
Diameter Well)	Diameter Well)

		Suction (Larger)
		Pipe from Well
To Household	Air Volume	Drive
		(Smaller)
Water System
	Control	Pipe
		Well
	Standard	Well
		Head
	Tank
	Air Volume
Priming Tee	Control Tube	Well Casing
and Plug		serves as
Relief Valve		Drive Pipe
		Venturi	24
	1835 0695		2P
			J
		Ejector	NO
			ET
	Suction Pipe	Nozzle
	From Well		1
Pressure	Drive Pipe	Foot Valve
		Strainer
Switch	To Well
Figure 4:Typical Deep Well Installations		Leather
		Cup Seals
		1834 0695

To Household
Water System
Pressure Gauge
and Priming Port	Relief Valve

	Drive
	Point
Built-in	Priming
	Tee and
Check	Plug
Valve

Check

Pre-Charged Valve

Tank

Drive point below water level

Drive

Coupling

Drive

Point

Cased	Open
Well	Water

Suction Pipe

From Well

Priming

Tee and

Plug

Sanitary

Well Seal

	Well
	Casing
Foot
Valve	10'	Foot
	Min.	Valve
	5–10'
Strainer

Screen

1836 0695

Figure 5:Typical Shallow Well Installations

Discharge Pipe and Pressure Tank Connections	5

	To Household
Pressure Gauge	Water System
and Priming
Plug	Relief
	Valve

	Pressure	From
	Switch
		Well

Figure 6: Pre-charged Tank

Connections

To Household

Water System

Air Volume

Control

Air Volume

Priming Tee Control Tube

and Plug

Relief Valve

276 0395

From

Pressure Well

Switch

Pre-Charge Tank Connection (Figure 6)

If your system uses a pre-charged tank, it should be connected to the pump as shown in Figure 6. The relief valve must be capable of passing the entire pump capacity at 100 PSI pressure.

Check the pre-charge of air in the tank with an ordinary tire gauge. the precharge is measured when there is no water pressure in the tank. Disconnect power to the pump and drain the tank before checking the pre-charge.

Your pump has a 30/50 PSI switch, so the tank pre-charge pressure should be 28 PSI (that is, it should be 2 PSI lower than the cut-in pressure of the pressure switch.

No AVC is required for a pre-charged tank; the 1/8” NPT AVC port on the pump body should be plugged.

Standard Tank Connection (Figure 7)

If your system uses a standard tank, connect it to the pump as shown in Figure 7. The relief valve used with a standard tank must be capable of passing the entire pump capacity at 75 PSI pressure.

Connect the Air Volume Control (AVC) tube to the 1/8” NPT AVC port on the pump body. Run the tubing from the pump’s AVC port to the AVC mounted on the tank. See the instructions provided with tank and AVC for details.

Sealing Pipe Joints

Use only PTFE pipe thread sealant tape or PTFE-based joint compounds for making all threaded connections to the pump itself. Do not use pipe joint compounds on plastic pumps: they can react with the plastic in pump components. Make sure that all pipe joints in the suction pipe are air tight as well as water tight. If the suction pipe can suck air, the pump will not be able to pull water from the well.

Figure 7: Standard Tank Connections

Electrical	6

Disconnect power before working on pump, motor, pressure switch, or wiring..

Motor Switch Settings

NOTICE: 1/3 and 1/2 HP motors are dual voltage and are factory set to 115 V. 3/4 & 1 HP motors are also dual voltage, but are factory set to 230 V. Motor terminal board (located under the motor end cover) should look like that shown below. Use the instructions to set your motor to match your power source.

Never connect a motor set to 115 V to a 230 V power source.

Plug Type Voltage Selector

Voltage is set to 230 V.. To change to 115 V:

Power Connections

Voltage Change Plug

Ground Wire Connection	Pressure Switch

Figure 8:Voltage set to 230 V, Plug Type

1.Make sure power is off.

2.Pull the voltage change plug off of the tabs.

3.Move the voltage change plug to the 115 V position. The plug will now cover 2 metal tabs and the arrow on the plug will line up with the 115V arrow on the label (see Figure 9).

Figure 9:Voltage set to 115 V, Plug Type

4.Attach the incoming power leads to the two outer screws on the pressure switch as shown in Figure 8.

5.Attach the ground wire to one of the grounding connections, shown in Figure 8.

6.If there are other wires, they should be capped.

7.Reinstall the motor end and pressure switch covers.

Dial Type Voltage Selector

Voltage is set to 230 V.. To change to 115 V:

Power Supply Connections

Voltage

Change

Dial

Pressure Switch

Ground Wire Connection

Figure 10:Voltage set to 230 V, Dial Type

1.Make sure power is off.

2.Turn the dial counter-clockwise until 115 shows in the dial window as shown in Figure 11.

Figure 11:Voltage set to 115 V, Dial Type

3.Attach the incoming power leads to the two outer screws on the pressure switch as shown in Figure 10.

4.Attach the ground wire to the grounding connections as shown in Figure 10.

5.If there are other wires, they should be capped.

6.Reinstall the motor end and pressure switch covers.

Electrical	7

Hazardous voltage.. Can shock, burn, or kill. Connect ground wire before connecting power supply wires. Use the wire size (including the ground wire) specified in the wiring chart. If possible, connect the pump to a separate branch circuit with no other appliances on it.

Explosion hazard.. Do not ground to a gas supply line.

Wiring Connections

Fire hazard.. Incorrect voltage can cause a fire or seriously damage the motor and voids the

warranty. The supply voltage must be within ±10% of the motor nameplate voltage.

NOTICE: Dual-voltage motors may be set for 115 V or 230 V. If necessary, reset the motor to the desired voltage, as shown. Do not alter the wiring in single voltage motors.

Install, ground, wire, and maintain your pump in compliance with the National Electrical Code (NEC) or the Canadian Electrical Code (CEC), as applicable, and with all local codes and ordinances that apply. Consult your local building inspector for code information.

Connection Procedure:

1.Connect the ground wire first as shown in Figure 8. The ground wire must be a solid copper wire at least as large as the power supply wires.

2.There must be a solid metal connection between the pressure switch and the motor for motor grounding protection. If the pressure switch is not connected to the motor, connect the green ground screw in the switch to the green ground screw under the motor end cover. Use a solid copper wire at least as large as the power supply wires.

3.Connect the ground wire to a grounded lead in a service panel, to a metal underground water pipe, to a metal well casing at least ten feet (3 m) long, or to a ground electrode provided by the power company or the hydro authority.

4.Connect the power supply wires to the pressure switch as shown in Figure 8.

Wiring Chart – Recommended Wire and Fuse Sizes

Model	HP	Max Load	Branch Fuse			Distance in Feet (Meters); Wire Size AWG (mm2)
		Amps	Rating Amps	0-100 (0-30)		101-200 (31-61)	201-300 (62-91)	301-400 (92-122)	401-500 (123-152)
115 Volts:
PLB	1/3	9.4	15	14 (2)			10 (5.5)
PLC	1/2					10 (5.5)			6 (14)
FLC, FSLCH		12.2					8 (8.4)	6 (14)
PLD	3/4		20	12 (3)
FLD, FSLDH		14.8
PLE	1					8 (8.4)	6 (14)		4 (21)
PLF	1-1/2	19.2	25	10 (5.5)				4 (21)
230 Volts:
PLB	1/3	4.7						14 (2)
PLC	1/2								12(3)
FLC, FSLCH		6.1					14 (2)
PLD	3/4		15		14 (2)			12 (3)
FLD, FSLDH		7.4
PLE	1								10 (5.5)
PLF	1-1/2	9.6					12 (3)	10 (5.5)

Preparing to Start the Pump - Deep Well	8

Open control valve as far as possible and fill pump and piping through priming port

or priming tee.

280 0395

Figure 12: Fill Pump

Replace all fill plugs and close control

valve completely.

556 0395

Figure 13: Prime Pump

A-Open Control Valve

Priming

Explosion hazard.. Never run pump against closed discharge. To do so can boil water inside pump, causing hazardous pressure in unit, risk of explosion and possibly scalding persons handling pump.

Risk of burns.. Never run pump dry. Running pump without water may cause pump to overheat, damaging seal and possibly causing burns to persons handling pump. Fill pump with water before starting.

1.Open the control valve as far as possible (see Figure 12). Then remove the priming plug from the pump and fill the pump, fill all piping between the pump and the well, and make sure that all piping in

the well is full. If you have also installed a priming tee in the suction piping, remove the plug from the tee and fill the suction piping.

2.Replace all fill plugs and close the control valve completely (Figure 13).

3.Power on! Start the pump and watch the pressure gauge. The pressure should build rapidly to 50 PSI as the pump primes.

4.After 2 or 3 minutes, the gauge should show pressure. If not, stop the pump, remove the fill plugs, reopen the control valve, and refill the pump and piping. You may have to repeat this two or three times in order to get all the trapped air out of the piping. Don’t forget to close the control valve each time before you start the pump.

5.When pressure has built up and stabilized at about 50 PSI, slowly open the control valve (see Figure 14) and let the pressure drop until the pressure gauge needle starts to flutter. When the needle flutters, close the valve just enough to stop the flutter (see Figure 14). Your pump is now operating at its most efficient point.

6.After the pump has built up pressure in the system and shut off, check the pressure switch operation by opening a faucet or two and running enough water out to bleed off pressure until the pump starts. The pump should start when pressure drops to 30 PSI and stop when pressure reaches 50 PSI. Run the pump through one or two complete cycles to verify correct operation. This will also help clean the system of dirt and scale dislodged during installation.

7.(PL Series pumps only). Check for leaks around band clamp. If pump is leaking, tighten clamp nut 1-2 turns. Do not overtighten.

NOTICE: Due to normal irregularities in the cup seal leather and the inner walls of the casing, packer jets do not form a perfect seal. In a dormant system, pressure will leak off over time, causing pump to cycle periodically to maintain system pressure level.

B-Watch for Pressure Gauge to Flutter
C-Close Control Valve until Pressure
Stabilizes	281 0395

Figure 14: Set Control Valve

Preparing to Start the Pump – Shallow Well	9

Open control valve as far as possible and fill pump and piping through priming port

or priming tee.

284 0395

Figure 15: Open Control Valve

Priming

Explosion hazard.. Never run pump against closed discharge. To do so can boil water inside pump, causing hazardous pressure in unit, risk of explosion and possibly scalding persons handling pump.

Risk of burns.. Never run pump dry. Running pump without water may cause pump to overheat, damaging seal and possibly causing burns to persons handling pump. Fill pump with water before starting.

1.Open the control valve as far as possible (see Figure 15). Then remove the priming plug from the pump and fill the pump, fill all piping between the pump and the well, and make sure that all piping in

the well is full. If you have also installed a priming tee in the suction piping, remove the plug from the tee and fill the suction piping.

2.Replace all fill plugs. Leave the control valve open (in a shallow well installation, the control valve always stays open).

3.Power on! Start the pump. The pump should pump water in two or three minutes.

4.If you don’t have water after 2 or 3 minutes, stop the pump and remove the fill plugs. Refill the pump and piping. You may have to repeat this two or three times in order to get all the trapped air out of the piping. The control valve remains open throughout this procedure.

5.After the pump has built up pressure in the system and shut off, check the pressure switch operation by opening a faucet or two and running enough water out to bleed off pressure until the pump starts. The pump should start when pressure drops to 30 PSI and stop when pressure reaches 50 PSI. Run the pump through one or two complete cycles to verify correct operation. This will also help clean the system of dirt and scale dislodged during installation.

6.(PL Series pumps only). Check for leaks around band clamp. If pump is leaking, tighten clamp nut 1-2 turns. Do not overtighten.

Winterizing the Pump

To prepare the pump for freezing temperatures:

1.Shut off power to the pump.

2.Relieve system pressure. Open a faucet and let it drain until water stops flowing.

3.Drain the pump. Your pump may have a separate drain plug. Remove this plug and let it drain.

Your pump may only have a plug or connection on the side of the pump. Remove this and let the pump drain. Some water will remain in the pump. A small amount of water left in the pump will not harm it if it freezes.

	Troubleshooting		10
	Symptom	Possible Cause(s)	Corrective Action
		Disconnect switch is off	Be sure switch is on.
		Fuse is blown or circuit breaker tripped	Replace fuse or reset circuit breaker.
		Starting switch is defective	DISCONNECT POWER; Replace starting switch.
			Refer to instructions on wiring (Page 9). DISCONNECT POWER; check and
	Motor will not run	Wires at motor are loose, disconnected, or	tighten all wiring.
						Hazardous voltage.. Capacitor voltage may be hazardous. To
		wired incorrectly				hold insulated handle screwdriver BY THE HANDLE and
				discharge capacitor,
			short capacitor terminals together. Do not touch metal screwdriver blade or
			capacitor terminals. If in doubt, consult a qualified electrician.
		Pressure switch contacts are dirty	DISCONNECT POWER and file contacts with emery board or nail file.
		Motor is wired incorrectly	Refer to instructions on wiring.
	Motor runs hot and overload	Voltage is too low	Check with power company. Install heavier wiring if wire size is too small (See
	kicks off		Electrical / Wiring Chart).
		Pump cycles too frequently	See section below on too frequent cycling.
		Pump in new installation did not pick up	In new installation:
		prime through:	1. Re-prime according to instructions.
		1. Improper priming	2. Check all connections on suction line, AVC, and ejector with soapy water or
		2. Air leaks	shaving cream.
		3. Leaking foot valve or check valve	3. Replace foot valve or check valve.
		Pump has lost prime through:	In installation already in use:
			1. Check all connections on suction line and shaft seal.
		1. Air leaks
			2. Lower suction line into water and re-prime. If receding water level in well
		2. Water level below suction pipe inlet
	Motor runs but no water is		exceeds 25’ (7.6M), a deep well pump is needed.
	delivered*	Foot valve or strainer is plugged	Clean foot valve or strainer.
		Ejector or impeller is plugged	Clean ejector or impeller.
		Check valve or foot valve is stuck shut	Replace check valve or foot valve.
	* Stop pump; then check	Pipes are frozen	Thaw pipes. Bury pipes below frost line. Heat pit or pump house.
	prime before looking for	Foot valve and/or strainer are buried in	Raise foot valve and/or strainer above bottom of water source. Clean foot valve
	other causes. Unscrew	sand or mud	and strainer.
	priming plug and see if
		Water level is too low for shallow well	A deep well jet will be needed if your well is more than 25’ (7.6M) depth to
	water is in priming hole.
		setup to deliver water	water.
	Pump does not deliver water to	Water level in well is lower than estimated	A new nozzle and venturi combination may be needed.
		Steel piping (if used) is corroded or limed,
	full capacity (Also check point 3		Replace with plastic pipe where possible, otherwise with new steel pipe.
		causing excess friction
	immediately above)
		Piping is too small in size	Use larger piping.
		Pressure switch is out of adjustment or	DISCONNECT POWER; adjust or replace pressure switch.
		contacts are welded together
		Faucets have been left open	Close faucets.
		Venturi, nozzle or impeller is clogged	Clean venturi, nozzle or impeller.
		Standard pressure tank is waterlogged and	Drain tank to air volume control port. Check AVC for defects. Check all
	Pump delivers water but does	has no air cushion	connections for air leaks.
		Pipes leak	Check connections.
	not shut off or pump cycles too
	frequently	Foot valve leaks	Replace foot valve.
		Pressure switch is out of adjustment	Adjust or replace pressure switch.
			DISCONNECT POWER and open faucets until all pressure is relieved. Using
			tire pressure gauge, check air pressure in tank at valve stem located on the tank.
		Air charge too low in pre-charged tank	If less than pressure switch cut-in setting (30-50 PSI), pump air into tank from
			outside source until air pressure is 2 PSI less than cut-in setting of switch. Check
			air valve for leaks (use soapy solution) and replace core if necessary.
		Pump is picking up prime	When pump has picked up prime, it should pump solid water with no air.
		Leak in suction side of pump	Suction pipe is sucking air. Check joints for leaks with soapy water.
	Air spurts from faucets
		Well is gaseous	Consult factory about installing a sleeve in the well.
		Intermittent over-pumping of well. (Water	Lower foot valve if possible, otherwise restrict pump discharge.
		drawn down below foot valve.)

Repair Parts	11

1
2	Diffuser
	(AL Series)
20
19	3
18
	4
	5
	6
	7		12
	8	11	13
	10

21

17

Service Kits:

Seal and Gasket Kit	PP1500
Overhaul Kit: 1/3 and 1/2 HP	PP1560
Overhaul Kit: 3/4HP	PP1565
Pressure Gauge Kit	PP2102
Pressure Switch Kit	PP2151

9

Diffuser (FSL/FL Series)

16

14

15

FSL/FL

Series

Repair Parts – Cast Iron Jet Pumps

Ref..	Part Description	Qty..	FSLCH-L, FLC-L 1/2 HP	FSLDH-L, FLD-L 3/4 HP
1	Motor	1	J218-582A-115-PKG	A100DLL
2	Water Slinger	1	17351-0009	17351-0009
3	Seal Plate	1	N3-1043P	N3-1043P
4	Seal Plate Gasket	1	N20-35	N20-35
5	Shaft Seal	1	U109-6A	U109-6A
6	Impeller	1	J105-40P	J105-86P
7	Diffuser	1	L1-25P	L1-48P
8	Diffuser, Screws	3	–	–
9	Diffuser Ring	1	L21-1	L21-1
10	Barbed Fitting – Straight	1	U111-211T	U111-211T
11	Pipe Plug, 1/8” Sq. Hd	1	U78-56ZPS	U78-56ZPS
12	Control Valve Assembly	1	01322	01322
13	Control Valve Gasket	1	L20-39	L20-39
14	Drain Plug		U78-941ZPV	U78-941ZPV
15	Priming Plug	1	U78-959T	U78-959T
16	Pump Body	1	L76-44	L76-44
17	Switch Tube	1	U37-672P	U37-672P
•	Barbed Fitting – Elbow	1	–	–
18	Pressure Switch	1	U217-1202	U217-1202
19	Lock Nut	1	U36-112ZP	U36-112ZP
20	Connector	1	L43-5C	L43-5C
21	3/8-16x1-1/2” Capscrews	4	U30-75ZP	U30-75ZP
22	Pressure Gauge		–	–
23	Pipe Plug, 1/2” Sq. Hd.	1	_	_

12 22 23

13

10

16

14

AL

11 Series

• Not illustrated.